Construction
Summary
The construction process for this project will not be divided up into the individual assemblies. Instead, parts that are more simple and easy to finalize will be made first. Machined parts will be prioritized over 3D printed ones, as 3D printed ones can be made when too busy to machine.
The most prominent machining process used for construction will be 3D printing, cutting, lathing and milling. Lathing and milling are necessary for creating axles with keyways and flat surfaces for set screws, while 3D printing excels at dealing with complicated geometry for casings and housings. Cutting allows the use of a single round for multiple parts at a time, drastically increasing the speed of machining for each individual part. Certain parts will also require minor finishing with the drilling machine or a power drill, as will most 3D printed parts. This is to ensure that all holes are the correct size before assembly.
Construction Examples
The image (Fig. 1) to the right shows the Collar (JRS_20-010) having a 3.5mm hole with 15mm depth drilled down its length, using a lathe.
The image (Fig. 2) shows the turning of a .4in aluminum rod down to 6mm using a lathe. This rod will be used for all axle segments, including parts JRS_20-008, JRS_20-012, JRS_20-013, JRS_20-014 and JRS_20-015.
This image (Fig. 3) shows the sanding of sharp edges on part JRS_20-010. This must be done to maintain cylindricity in the shaft, which will be required to fit inside the gear bore.
This image (Fig. 4) shows the drilling of holes into the transmission gear mount, part JRS_20-017.
This image (Fig. 5) shows the drilling of a hole into the collar JRS_20-010. The hole is drilled in preparation of tapping to accommodate a set screw, size 6-32.
This video (Fig. 6) demonstrates the drilling of screw holes into the Shell Top (JRS_20-013. These holes were drilled with a #25 drill.
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Design Decisions
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Drawing Tree
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